The Mk1 ABF Project

[cartertronic]

Hey all,

So ... this is hopefully the first post in a long thread covering my planned conversion, a 2L 16V ABF into my 76' Mk1 2dr.

The plan isn't to build a track car or even a high-powered road car.
The plan is to build a daily drivable mk1 with enough power to make it great fun to drive.. for me that's somewhere around 170bhp (saying that I'll probably be bored 6months later! ).
Keeping within the theme of drivability/usability, I'm going to try and install the factory AC system as well.

I'm going to attempt this project on a fairly strict budget, so most of the decisions made will be a balance between cost and practicality. I'm hoping to keep it under $3000.. wish me luck!

The engine has been purchased in the form of a 97' Mk3 GTI. It's in the UK at the moment being removed by a mate of mine Alastair (aka 'Young Timer'). I went for a complete car so I could get everything I needed (ECU, ignition barrel + keys for ECU immobiliser, loom, fuse box, AC etc..) in one hit.

I'll update the research I've already done, and as I go I'll try to keep a running tally of expenses, problems and discoveries to help anyone planning this conversion.

Expenses so far:
-Car (ebay) £461 ($840AU)
-Towing to Alastair's place £165 ($300AU)

Engine Specs:
-110 kilowatts (150 PS; 148 bhp) @ 6,000 rpm; 180 newton metres (133 ft·lbf) @ 4,800 rpm (ABF)
-109,000 miles (175,000 km) - a little higher then I would've liked, but for the price of the car its not too bad.

The plan is to strap it to my 020 4T 5spd, and sell the 02A gearbox, 288mm front brakes, and MC+Booster to cover as much of the costs as possible.

Here's a pic

[WABIT]

GET INTO IT!!!! HELL YEAH!! hopefully someone can have a WORKING!! 16v in a mk1

dom

[Jarred]

yea well done Simon, will be super cool to see this all done!

[Golf Loon]

Nice project, the 4T Gearbox is just about the best one you could use for the job.

[Preen59]

Way to go dude.

Be looking forward to following the progress on this bad boy!

[16v_kid]

Really looking forward for this one.

You interested to sell the O2A box? pm me if so.

Good luck in the build.

[Jarred]

...You interested to sell the O2A box? pm me if so.
..

... and sell the 02A gearbox,

Bro he said he was going to sell the 02A, read!
How bout you PM him if you're so interested in it!

[cartertronic]

Thanks all! Hopefully it all goes smoothly enough

I should give you a quick run down of the car the engine is being installed into:

1976 Mk1 2dr
-16x7 Autostrada Modena's with 205/45's
-Lowered Cup Kit
-Cordoba rear drums, 22mm MC and booster
-Replacing a 1.8L Kjet (76kw - 102bhp)
-020 4T 5spd
-Extractors
-2 inch exhaust system

There are a few problems that are foreseeable and I have been researching, I'll update them all to be thorough.

EXHAUST MANIFOLD
First off the bat is the exhaust manifold problem all 16v converters should be familiar with...

There are two obvious options:

Making a Downpipe (for reference ABF, 9A & KR have the same exhaust manifold)
http://www.clubgti.com/FORUM/archive...?t-140869.html
http://www.clubgti.co.uk/forum/showthread.php?t=128209

Buying Extractors/Headers
http://www.vwwatercooled.org.au/newf...ad.php?t=23414
http://www.vwwatercooled.org.au/newf...ght=extractors


I think I'm going to buy a set, but realistically it has to be a relatively cheap option.

At this stage its either:
-http://www.ashleyexhausts.co.uk/p1411115.htm - £200 ($365AU) could be sent with car (postage within UK £12.50 / $23AU).
-http://www.racelandus.com/p-6-racela...16v-74-84.aspx who do a Mk1 16v header for $230US ($145US + $85US shipping) which is only like $265AU!

Unfortunately, the US mob will have designed theirs for LHD, but does that definitely mean it will foul? Is it possible to modify it to overcome this? If it can be easily overcome then it looks a good option..

In the mean time I've emailed there Belgian parent company http://www.raceland.nl/eshop/catalog/ to see if they do a RHD version.

Anyone have any thoughts or suggestions?

[peedman]

Have you thought about getting someone here to custom make it? I will have an exhaust manifold for an abf for sale eventually but im pretty sure it wont fit ur car. It was custom made here (previous owner) and i got it ceramic coated. You can buy laser cut 16v exhaust flange from 034 motorsport so that might be an option...

And i think lhd and rhd is the same since the booster is on the same side in a mk1, correct me if im wrong.

[Jarred]

...And i think lhd and rhd is the same since the booster is on the same side in a mk1, correct me if im wrong.

i think the problem is fouling on the steering rack where it comes out of the firewall.